Challenge
STG, a leading tobacco goods manufacturer, faced significant challenges driven by increasing production demands, a shortage of skilled labor, and the need to manage rising operational costs. to mintain it's competitive position STG sought an innovative solution to automate its production logistics. The existing processes were manual, labor-intensive, and prone to inefficiencies that resulted in machine downtime, operational disruptions, and transportation damages. These issues, combined with the need for enhanced workplace safety and accuracy in handling various pallet types, prompted STG to explore a scalable, cost-effective automation system to future-proof its operations.
The solution
To tackle these challenges, Nipper implemented two nipper AGV's in combination with 4 pallet dispensers, linked to the production flow.
- Hall 3 to Hall 4 transport: One Nipper moves magazines containing molding caps between halls, eliminating repetitive manual trips.
- Outbound logistics: A second Nipper manages the full pallet flow, starting with pallet dispensers for delivering or picking up empty pallets and transporting loaded pallets from production through a strapper, wrapper and finally to the outbound dock.
Employees received a 4 day training on programming and operating the Nippers, ensuring a smooth transition to automation and full knowledge to adjust routes and flows.
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Results
With the implementation of Nipper’s automation solution, STG achieved the following results:
- Reduced operational costs: The advanced system led to a 35% reduction in operational costs by enhancing machine performance and lowering labor expenses.
- Increased safety: Automation improved workplace safety by reducing the need for manual intervention, decreasing the likelihood of workplace accidents.
- Enhanced operational accuracy: The automation system increased the precision of operations, reducing errors and improving overall efficiency.
- Minimized machine downtime: The system significantly reduced machine downtime, leading to fewer disruptions and product transport damages.
- Reduced investment costs: STG realized a 40% savings compared to alternative solutions, thanks to the cost-effective automation system.
- Scalability and reliability: The solution provided a reliable, scalable, and future-proof platform, enabling STG to meet growing production demands and remain competitive.
Find out just how easy the move towards smart can be
From the Nipper Stretch Hood to the intelligent Nipper AGV, all Nipper’s products have been designed as building blocks. They work seamlessly together with our roller conveyor, pallet elevator, turntable, and traverse systems. And can also easily be integrated into existing logistics processes and plants.